News and articles from Topstar

Many injection molding plants fail to maintain a stable mold temperature of 160°C when producing high-temperature polymers, resulting in numerous scraps, rework, and mold damage. For example, a medical product manufacturer scrapped 1,200 PEEK components last year because its mold temperature was consistently maintained at 145°C—flow lines and warpage rendered these components unusable. Therefore, mastering… Continue reading Mastering the 160℃ mold temperature controller: Which materials require 160℃?

Damage to the clamping platen in an electric injection molding machine can lead to unplanned downtime, parts scrap, and additional emergency repair costs. As an injection molding machine manufacturer, we recognize that the root cause lies in insufficient platen design strength, which cannot withstand the high precision and high-strength forces required by electric injection molding… Continue reading How to solve platen damage problems: High-rigidity platen design for electric injection molding machine

Two common mistakes are easily made when injection molding TPU/TPE: using injection pressures below 1400 kgf/cm² and using standard (non-nitrided) screws and barrels. TPU and TPE offer unparalleled flexibility and durability, but their unique flowability and abrasion resistance require specialized process control to achieve optimal results. Therefore, several key considerations must be taken into account… Continue reading Injection Molding of Flexible Materials: Precautions for TPU/TPE Processes

Unplanned downtime in injection molding often stems from nozzle clogging, resulting in an average loss of hundreds of dollars per hour in production. A Michigan-based auto parts manufacturer reported losing over a dozen hours per month due to nozzle clogging, resulting in significant waste of production time. Nozzle clogging, caused by solidified molten plastic or… Continue reading Learn how to quickly solve molding machine nozzle clogging problems in 5 minutes

Unstable plasticization, inaccurate demolding, and excessively long production cycles lead to significant losses in production efficiency. On average, each factory loses tens of thousands of dollars annually due to PP material waste and failure to meet production targets. As product managers at Topstar, we’ve heard many clients raise these issues. One large home appliance brand… Continue reading Case Study: Injection Molding of Rice Cooker Shell Using a 260-Ton Injection Molding Machine

A 2024 survey found that 32% of production scrap and 18% of cycle time extensions in injection molding were attributed to poorly performing mold temperature controllers. In actual production, a water-type mold temperature controller operating with a 2°C deviation can reduce yield from 95% to 85% overnight. You can’t just set up a mold temperature… Continue reading 2025 Optimization Checklist: Methods to Improve the Performance of Any Mold Temperature Controller

Manufacturers across many regions lose 15% to 20% of their production time due to communication delays and parameter loss in traditional hydraulic or basic electric injection molding machines. For a 24/7 factory, this translates to 1,080 hours of wasted production annually and millions of dollars in lost revenue. Even worse, 4% to 8% of parts… Continue reading Digital Platform All Electric Injection Molding Machine: Enhance Efficiency & Parameter Control

Every year, many manufacturers waste 5-10% of their raw materials due to degradation, equivalent to significant resource losses for a medium-sized enterprise operating 24/7. Worse still, these manufacturers fail to realize that degradation is the root cause of part defects. As an injection molding machine manufacturer, I’ve found that 70% of degradation cases are due… Continue reading How can I prevent material degradation by adjusting the molding machine barrel temperature?

The global plastic water cup market produces over 50 billion units annually. For these manufacturers, every second of cycle time translates into real profit. Even a two-second reduction in production per cup can save hundreds of millions of dollars for a 24/7 factory. However, many water cup manufacturers report inefficiencies in their factories, such as… Continue reading 170ton injection molding machine: Water cup injection molding production

According to a survey by the Mobile Phone Accessories Market Report, 65% of US consumers prefer soft PU phone cases due to their superior feel, anti-slip properties, and shock absorption, making them one of the best-selling phone case types. However, many cases suffer from uneven softness, surface bubbles, or incomplete mold filling. One Indian customer… Continue reading How to successfully produce soft PU phone cases on a mobile cover making machine？

One customer we worked with told us they were previously rejecting 15% of their thick-walled battery casing batches due to warpage. This issue was resolved after they switched to a Topstar 120°C mould temperature controller. Now, they’ve achieved a 98% yield and reduced cycle time by 10%. In injection moulding, a deviation of just 0.5°C… Continue reading 120°C mould temperature controller: Which industries are suitable for 120°C

Inadequate monitoring of molding machine performance in injection molding production can lead to scrap, rework, and financial losses. As a Topstar injection molding machine user, you are responsible for your production results when using our machines. Therefore, we have leveraged our experience as a manufacturer to provide you with five performance indicators to track during… Continue reading 5 key performance indicators to track in molding machine production